Abstract: Fiber-containing products are described that include a cured binder formed from a binder composition that may include a sugar alcohol having three or more carbon atoms, and a polymeric polycarboxylic acid. The binder composition may be characterized by a mole ratio of hydroxyl groups to carboxylic acid groups greater than or about 1.1:1. The fiber-containing product may also be characterized by a thermal stability that is greater than a comparative fiber-containing product made with a comparative cured binder that includes the polymeric polycarboxylic acid but lacks the sugar alcohol. The fiber-containing products may include thermal insulation products such as building insulation, pipe insulation, duct insulation, and appliance insulation.

Abstract: Processes of making a non-woven glass fiber mat are described. The process may include forming an aqueous dispersion of fibers. The process may also include passing the dispersion through a mat forming screen to form a wet mat. The process may further include applying a carbohydrate binder composition to the wet mat to form a binder-containing wet mat. The binder compositions may include a carbohydrate, a nitrogen-containing compound, and a thickening agent. The binder compositions may have a Brookfield viscosity of 7 to 50 centipoise at 20° C. The thickening agents may include modified celluloses such as hydroxyethyl cellulose (HEC) and carboxymethyl cellulose (CMC), and polysaccharides such as xanthan gum, guar gum, and starches. The process may include curing the binder-containing wet mat to form the non-woven glass fiber mat.

Abstract: A roofing membrane includes a thermoplastic polyolefin (TPO) layer and a polyvinyl chloride (PVC) layer. The TPO layer forms a bottom layer of the roofing membrane, and the PVC layer is positioned atop the TPO layer so that the PVC layer forms a top layer of the roofing membrane. The TPO layer and the PVC layer are configured to be chemically compatible so that the TPO layer and the PVC layer are chemically bonded and function as a single roofing membrane. Compatibilizing includes at least one of (i) adding a compatibilizing agent to at least one of the TPO material and the PVC material prior to extrusion and (ii) positioning at least one compatibilizing film, prior to bonding, between the TPO material and the PVC material.

Abstract: A glass facer for a constructions board includes a first non-woven layer of coarse fibers and a second non-woven layer of coarse fibers and microfibers. The glass facer also includes a binder that simultaneously binds or adheres the coarse fibers of the first non-woven layer together, the coarse fibers and the microfibers of the second non-woven layer together, and the first non-woven layer to the second non-woven layer. The first non-woven layer has a porosity and air permeability that enables the first non-woven layer to absorb a material of the construction board when the glass facer is positioned atop the construction board during manufacture of the construction board. The second non-woven layer is configured to block the material of the construction board from passing through the glass facer to an exterior surface of the second non-woven layer so that the material is not externally visible.

Abstract: A pipe insulation product including a core of insulating material and a laminate surrounding the core and bonded to the core. The core may include an outer surface; an inner surface; and a wall extending between the outer and inner surfaces. The laminate may include a foil or metallized polymeric film sheet, a scrim, a porous media sheet, and a polymeric film sheet bonded together via an adhesive. The laminate may include a closure flap that is configured to adhesively seal opposite ends of the laminate together to form a cylindrical tube with the core enclosed therein. The closure flap may be configured to include a curl that provides a greater closure flap adhesive seal.

Abstract: A system for manufacturing a thermoplastic prepreg product includes a belt or conveyor, a prepreg applicator that positions a thermoplastic prepreg atop the belt or conveyor, a foam applicator that applies a foam mixture atop the thermoplastic prepreg, a heating mechanism that heats the thermoplastic prepreg and the foam mixture to cause the foam mixture to react atop the thermoplastic prepreg, and a laminator that is configured to press the thermoplastic prepreg and foam mixture to control a thickness of the resulting thermoplastic prepreg product. The thermoplastic prepreg includes a fabric, mat, or web of fibers and a thermoplastic material that is impregnated within the fabric, mat, or web of fibers. The thermoplastic material is formed from in situ polymerization of monomers and oligomers. The foam mixture includes an isocyanate, a polyol blend, and a blowing agent.

Abstract: A method for applying a roofing membrane may include unrolling an adhesive material onto a roofing board to adhere a bottom surface of the adhesive material to the roofing board. The method may include removing a release liner from the adhesive material to expose a top surface of the adhesive material. The method may include applying a roofing membrane to the exposed top surface of the adhesive material to adhere the roofing membrane to the roofing board.

Abstract: An insulation product may include an insulation material. The insulation material may include at least one material selected from the group consisting of nonwoven insulation, aerogel insulation, mineral insulation, and foam insulation. The insulation material may include a first end and a second end positioned opposite the first end. The first end may include a protrusion. At least a portion of the protrusion may widen in a direction opposite the second end. The second end may define a cutout that substantially matches a size and shape of the protrusion. The cutout and the protrusion may be aligned with one another along a length of the insulation material.

Abstract: Binder compositions are described that include a phenol, a urea compound, formaldehyde, and at least one cyclic urea-dialdehyde compound. The cyclic urea-dialdehyde compound forms crosslinking bonds between polymers of phenol-urea-formaldehyde when the binder composition is cured. Also described are methods of making fiberglass insulation products using the above-described binder compositions. The methods may include contacting the binder composition with glass fibers and forming an amalgam of the binder composition and the glass fibers. The amalgam may be heated to form mats of the glass fibers and binder. The mats may be processed into the fiberglass insulation products.

Abstract: Embodiments may include a coated granule for roofing systems. The coated granule may include an aluminum silicate granule and a coating disposed on the aluminum silicate granule. The coating may include a copolymer and a siloxane-based or a silane-based compound. The copolymer may be a cationic fluorinated (meth)acrylic copolymer. The aluminum silicate granule may have a particle size in a range from 0.2 mm to 2.4 mm. The aluminum silicate granule may have a 65% or greater reflectivity. The coated granule may repel oil and maintain its reflectivity better than with other techniques.

Abstract: According to one embodiment, a system for manufacturing a fully impregnated thermoplastic prepreg includes a mechanism for moving a fabric or mat and a drying mechanism that removes residual moisture from at least one surface of the fabric or mat. The system also includes a resin application mechanism that applies a reactive resin to the fabric or mat and a press mechanism that presses the coated fabric or mat to ensure that the resin fully saturates the fabric or mat. The system further includes a curing oven through which the coated fabric or mat is moved to polymerize the resin and thereby form a thermoplastic polymer so that upon exiting the oven, the fabric or mat is fully impregnated with the thermoplastic polymer. During at least a portion of the process, humidity in the vicinity of the coated fabric or mat is maintained at substantially zero.

Abstract: Fiber-containing composites are described that contain woven or non-woven fibers, and a cured binder formed from a binder composition that includes (1) a reducing sugar and (2) a crosslinking agent that includes a first carbon moiety selected from an aldehyde, a ketone, a nitrile, and a nitro group, wherein an ?-carbon atom having at least one acidic hydrogen is directly bonded to the first carbon moiety. Exemplary reducing sugars include dextrose and exemplary crosslinking agents include glyoxal. Exemplary fiber-containing composites may include fiberglass insulation.

Abstract: Fiber-containing composites are described that contain woven or non-woven fibers, and a cured binder formed from a binder composition that includes (1) a reducing sugar and (2) a crosslinking agent that includes a first carbon moiety selected from an aldehyde, a ketone, a nitrile, and a nitro group, wherein an ?-carbon atom having at least one acidic hydrogen is directly bonded to the first carbon moiety. Exemplary reducing sugars include dextrose and exemplary crosslinking agents include glyoxal. Exemplary fiber-containing composites may include fiberglass insulation.

Abstract: Some embodiments of the present technology may encompass pipe insulation systems. The insulation systems may include an insulation member having an inner surface and an outer surface. The insulation systems may include a protective cladding having an interior surface and an exterior surface. The interior surface of the protective cladding may be disposed about the outer surface of the insulation member. The interior surface of the protective cladding may include an embossed texture formed from a plurality of protruding features and a plurality of recessed features. The plurality of protruding features may extend at least 1 mm beyond the plurality of recessed features.

Abstract: A carpet tile includes a textile top member and a cushion mat that is coupled with the textile top member via a thermoplastic material. The textile top member includes carpet yarns and a backing that is coupled with the carpet yarns so that the backing structurally supports the carpet yarns. The cushion mat includes a polymeric material component having polymer fibers that are randomly oriented and entangled together and a scrim reinforcement that is disposed within the polymeric material component. The scrim reinforcement reinforces and stabilizes the polymeric material component and is entirely covered and concealed by the intermeshed polymer fibers.

Abstract: A thermoplastic composite sheet may be composed of a polymer material matrix and a lightweight material that is disposed throughout the polymer material matrix. The polymer material matrix may extend continuously throughout a length, width, and thickness of the thermoplastic composite sheet. The polymer material matrix may be a fully polymerized thermoplastic material. The lightweight material may be fully saturated by the thermoplastic material of the polymer material matrix. The thermoplastic composite sheet may include between 50 and 99 weight percent of the thermoplastic material and between 1 and 50 weight percent of the lightweight material. The thermoplastic composite sheet may be free of reinforcing fibers.

Abstract: A method of using a self-stick insulation. The method includes providing a piece of insulation product with an adhesive coating. The adhesive coating includes polystyrene-maleic anhydride (SMA) and/or polyacrylic acid (PAA); an alcohol amine; and at least one of a polyvinyl alcohol and a starch. The adhesive coating is then activated with liquid water. Once the adhesive coating is active, the insulation product is attached to a surface with the adhesive coating.

Abstract: A carpet tile includes a textile top member and a carrier mat that is coupled with the textile top member via a thermoplastic material. The textile top member includes carpet yarns and a backing that is coupled with the carpet yarns so that the backing structurally supports the carpet yarns. The carrier mat includes a polymeric material component, a reinforcement, and a binder that is uniformly distributed throughout the polymeric material component and reinforcement component. The polymeric material component includes polymer fibers that are randomly oriented and entangled together. The reinforcement is disposed within the polymeric material component so that the reinforcement is entirely covered and concealed by the entangled polymer fibers to prevent exposure to a user. The reinforcement mechanically reinforces and stabilizes the polymeric material component and carpet tile.

Abstract: According to one embodiment, an insulation blanket for insulating a structure includes a first facer layer and a second facer layer. A plurality of intermeshed non-woven glass fibers are disposed between the first and second facer layers and a fumed silica insulating powder is also disposed between the first and second facer layers. The fumed silica insulating powder has an average particle size of between about 2 and 20 nanometers. The insulation blanket includes at least one exposed edge having a cauterized face that forms a barrier on the exposed edge to encase the fumed silica insulating powder within the interior of the insulation blanket, which minimizes degradation of the insulating value due to loss or shedding of the fumed silica insulating powder through the exposed edge. The cauterized edge has a depth of cauterized material of between about 0.05 mm and 3 mm.

Abstract: The present disclosure relates generally to duct liner insulation products for curvilinear ducts, and more specifically relates to methods and materials to universally fit duct liner insulation for lining oval ducts in air conditioning, heating, and ventilating (HVAC) systems. A duct liner insulation for a curvilinear duct is provided that includes an insulation layer configured to line an interior surface of a curvilinear duct when installed within the curvilinear duct. The duct liner insulation also includes an elastically deformable layer configured to compress the insulation layer against the interior surface of the curvilinear duct when installed within the curvilinear duct such that the insulation layer extends substantially uniformly around an inner periphery of the curvilinear duct.